Ford has been grappling with numerous recalls over the past few years, and 2024 is poised to be the most challenging yet. The most recent recall, marking Ford's 46th this year, involves 90,736 vehicles equipped with either 2.7-liter or 3.0-liter EcoBoost V-6 engines. These engines are susceptible to intake valve failure, which can lead to severe engine damage. The affected models include the F-150, Bronco, Edge, and Explorer, as well as the Lincoln Nautilus and Aviator from the 2021 and 2022 model years.
The issue stems from the intake valves, which could break and fall into the combustion chamber, causing significant engine failure. This problem is not unique; the National Highway Traffic Safety Administration (NHTSA) documents reveal 328 customer complaints, 487 warranty claims, and 809 engine replacements. An investigation revealed that the faulty valves were made from a material called Silchrome Lite, which can become brittle when overheated during manufacturing.
In response, Ford switched to a different alloy in October 2021, which is less prone to overheating. Despite this change, Ford is proceeding with a broad recall, believing that many of the potentially defective valves have already failed. The recall strategy, however, is puzzling as it does not involve replacing the valves. Instead, dealers will inspect the vehicles to assess their engine cycle count and perform a service procedure involving high-rpm engine cycles on those that do not meet the threshold, with engines being replaced if they fail this test.
This recall echoes a previous NHTSA investigation in 2022 concerning engine failures in the Ford Bronco. This latest recall includes 15,835 Broncos with the 2.7L and 3.0L engines, with the F-150 being the most affected model at 47,719 vehicles. Dealers will start notifying owners of the recall on September 30, with individual owner notifications following on October 7.
